Inspection Checklist For Process Unit Horizontal Heat Exchanger

Report No.: Date prepared:Equip. Tag. & Service: Location/Area:Date Inspected: Reason for Inspection:

Inspected by Refinery Inspector:

Approved by Snr. Supv. (R&M):

Equipment data:DESCRIPTION SHELL TUBE DESCRIPTION SHELL TUBEMaterial Design Pressure (psig)Thickness (in) Design Temperature (°F)Corrosion Allowance (in) Hydro Test Pressure (psig)

A=Acceptable, U=Un-acceptable, NA=Not Applicable, NI=Not InspectedNO. ITEM A U NA NI REPAIRS TO BE DONE/COMMENTS1.0 Channel Head, Cover and Nozzles

1.1Internal Erosion/Cracking/Corrosion (scales, pits, buildup) Describe location, appearance and depth.

1.2 Excessive scale presence. Describe

1.3 Weld condition/corrosion & condition of Pass partition plate

1.4 Condition of gasket surfaces1.5 UT measurement- Channel and Nozzles

1.6 Internal and external cracks, erosion/corrosion, foreign deposit

1.7 Insulation condition

1.8 Condition of attachment welds (Includes Lift lugs, etc.)

1.9 Channel cover

1.10 Check instrument connection for corrosion damage

1.11 External coating/painting condition

2.0 Cylindrical Shell

2.1Internal Erosion/Cracking/Corrosion (scales, pits, buildup) Describe location, appearance and depth.

2.2 Excessive scale presence. Describe

2.3 Weld condition/corrosion (both longitudinal and circumferential)

2.4 UT measurements-shell and nozzles

2.5 Inspect the inlet, outlet nozzles for corrosion, erosion and thinning.

2.6 Check the condition of attachment and welds (Includes Lift lugs, pipe supports

etc.) for cracks.2.7 Inspect gasket faces.

2.8 Condition of external paint, insulation.

3.0 Tube Bundle

3.1Check tube ID & OD fouling. Describe the extent of fouling and locations.

3.2 Measure ID and OD and compare to the original for metal loss.

3.3Visually inspect ID and OD for pits measure the depth of pit.

3.4 Inspect tube ends for corrosion thinning.

3.5 If tube to tube-sheet welded, then perform DP test to ensure no crack.

3.6 Check the tube sheet for corrosion, erosion and any mechanical damage

Notes:

3.7 Eddy current testing and evaluation of the tube condition.

3.8 Mark defective tubes for plugging or re-tubing as required.

3.9 Check baffles plates for corrosion, thinning and enlarged tube holes.

3.10 Check tie-rods for corrosion & damage.

4.0 Floating Head Cover4.1 Check for corrosion, erosion & pits

4.2Check gasket face for corrosion, erosion, pit or mechanical damage.

5.0 Shell Cover5.1 Check for corrosion, erosion & pits

5.2 Check gasket face for corrosion, erosion, pit or mechanical damage

5.3 UT check

5.4 Check vent and drain for blockage and corrosion thinning

6.0 Foundation/Supports

6.1 Condition of support saddle and fire proofing

6.2 Condition of support bolts6.3 Condition of foundation

6.4 Unit supported correctly, no evidence of piping strain

6.5 Foundation bolts loosen one end for shell expansion

6.6 Grounding lug intact

7.0 Hydrostatic Testing

7.1 Test from shell side: Design x 1.5 (Built before 1999) and Design x 1.3 (after 1999)

7.2 Test from Tube side # Design x 1.5 (Built before 1999) and Design x 1.3 (after 1999)

7.3Final Test from shell side # Design x 1.5 (Built before1999) and Design x 1.3 (after 1999)

Notes: